Composite floor with integrated conduit

ABSTRACT

A cargo vehicle is disclosed having a composite floor assembly with at least one conduit extending along a length of the composite floor assembly. The at least one conduit may include a first internal cavity and a second internal cavity. The first internal cavity may be configured to route at least one vehicle component. The second internal cavity may be configured to receive at least one vehicle component or a plurality of mechanical fasteners. The mechanical fasteners may be used to couple a base rail to the composite floor assembly.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/748,857, filed Oct. 22, 2018, the disclosure of which ishereby expressly incorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to composite floor structuresand methods of making the same. More particularly, the presentdisclosure relates to composite floor structures of cargo vehicles withone or more conduits configured to route vehicle components and methodsof making the same.

BACKGROUND OF THE DISCLOSURE

Cargo vehicles are used in the transportation industry for transportingmany different types of cargo. Cargo vehicles may be constructed usingcomposite materials, which may lead to an absence of or reduction inmetallic and wood materials and associated advantages, includingsimplified construction, thermal efficiency, reduced water intrusion andcorrosion, and improved fuel efficiency through weight reduction, forexample. Cargo vehicles constructed using composite materials may alsoallow for maximizing the amount of interior storage space of the cargovehicle while maintaining a suitable overall height of the cargovehicle. Maximizing the amount of interior storage space may occur when,for example, a connection height between a rear slide rail assembly anda composite floor assembly is minimized. Minimizing the connectionheight between the rear slide rail assembly and the composite floorassembly may make it desirable to route vehicle components, such as airhoses or electrical cables, through an internal path of the cargovehicle. Moreover, it is desirable to route the vehicle componentsthrough an internal path in order to limit the exposure of the vehiclecomponents to weather and road debris.

SUMMARY OF THE DISCLOSURE

A cargo vehicle is disclosed having a composite floor assembly with atleast one conduit. The conduit may be used to internally route vehiclecomponents, such as an air hose and/or an electrical cable, along alength of the composite floor assembly. The conduit may be adhered tothe composite floor assembly and assist in coupling the composite floorassembly to sidewalls of the cargo vehicle.

According to an exemplary embodiment of the present disclosure, a cargobody is provided including a composite floor assembly having a firstlongitudinal end and a second longitudinal end spaced apart from thefirst longitudinal end along a floor longitudinal axis. The cargo bodyfurther includes a first conduit coupled to the composite floor assemblyand including a first and a second internal cavity. The first and secondinternal cavities of the first conduit may extend along a length of thefirst conduit parallel to the floor longitudinal axis.

According to another exemplary embodiment of the present disclosure, acargo body is provided including a composite floor assembly having aplurality of transverse composite beams oriented generally perpendicularto a longitudinal axis of the composite floor assembly. A firstlongitudinal end of each of the plurality of transverse composite beamsdefines a first side of the composite floor assembly and has a firstshape. The cargo body further includes a first conduit coupled to thefirst side of the composite floor assembly. The first conduit includes afirst wall having a second shape complementary to the first shape.

According to a further exemplary embodiment of the present disclosure, aconduit for a base rail for a floor assembly of a cargo body is providedincluding an exterior boundary defined by at least a first wall, asecond wall, and a third wall. The second wall intersects the firstwall, and the third wall intersects at least one of the first and secondwalls. The conduit further includes a midwall coupled to at least one ofthe first, second, and third walls. In addition, the midwall defines afirst internal cavity and a second internal cavity.

According to another exemplary embodiment of the present disclosure, acargo body is provided having a front end, a rear end, a longitudinalaxis extending from the front end to the rear end, a left side, and aright side. The cargo body includes a composite floor assembly, acomposite sidewall extending in a direction parallel to the longitudinalaxis, a base rail coupling the composite sidewall to the composite floorassembly, and a conduit disposed between the base rail and the compositefloor assembly. The conduit includes a first internal cavity configuredto route at least one vehicle component and a second internal cavityconfigured to receive a plurality of fasteners that couple the base railto the conduit.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiments exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the intended advantages of thisinvention will become more readily appreciated as the same becomesbetter understood by reference to the following detailed descriptionwhen taken in conjunction with the accompanying drawings.

FIG. 1 is a top perspective view of an exemplary semi-trailer of thepresent disclosure including a composite floor assembly;

FIG. 2 is a bottom perspective view of the exemplary semi-trailer ofFIG. 1, shown with a conduit coupled to the composite floor assembly;

FIG. 3 is a partial perspective exploded view of the exemplarysemi-trailer of FIG. 1, shown with the conduit coupled to the compositefloor assembly;

FIG. 4 is a detail view of the conduit coupled to the composite floorassembly of FIG. 2;

FIG. 5 is a detail exploded view of the conduit coupled to the compositefloor assembly of FIG. 2;

FIG. 6 is a partial cross-sectional view of the exemplary semi-trailerof FIG. 1, shown with the conduit coupled to the composite floorassembly and a base rail coupling a sidewall to the conduit;

FIG. 7 is a cross-sectional view of the conduit of FIG. 4;

FIG. 8 is a flow chart of exemplary method for manufacturing thecomposite floor assembly of FIG. 1; and

FIG. 9 is a cross-sectional view of one of a plurality of transversecomposite beams of the composite floor assembly of FIG. 2.

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of various features and components according to the presentdisclosure, the drawings are not necessarily to scale and certainfeatures may be exaggerated in order to better illustrate and explainthe present disclosure. The exemplification set out herein illustratesan embodiment of the invention, and such an exemplification is not to beconstrued as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principals of theinvention, reference will now be made to the embodiments illustrated inthe drawings, which are described below. The embodiments disclosed beloware not intended to be exhaustive or limit the invention to the preciseform disclosed in the following detailed description. Rather, theembodiments are chosen and described so that others skilled in the artmay utilize their teachings. It will be understood that no limitation ofthe scope of the invention is thereby intended. The invention includesany alterations and further modifications in the illustrative devicesand described methods and further applications of the principles of theinvention which would normally occur to one skilled in the art to whichthe invention relates.

1. Semi-Trailer

Referring initially to FIG. 1, a semi-trailer 100 is shown forsupporting and transporting cargo. The illustrative trailer 100 extendsalong a longitudinal axis A from a front end 102 to a rear end 104. Theillustrative trailer 100 includes a cargo body 110 with a floor assembly112, a roof 114, a right sidewall 116R, a left sidewall 116L, a frontwall or nose 118, and a rear door assembly 120 having a rear frame 122and a door (not shown) to access the cargo body 110.

Moving from the front end 102 to the rear end 104, the trailer 100 alsoincludes a coupler assembly 130 having a king pin 131 (see FIG. 3)configured to couple the cargo body 110 to a motorized tractor oranother vehicle (not shown), a landing gear assembly 132 configured tosupport the cargo body 110 on the ground, a fuel tank assembly 134, anda slide rail assembly (not shown) configured to couple the cargo body110 to a rear wheel assembly (not shown). The front end 102 of the cargobody 110 may be supported atop the tractor (not shown) via the couplerassembly 130 in a transport condition or atop the landing gear assembly132 in a stationary condition, and the rear end 104 of the cargo body110 may be supported atop the wheel assembly (not shown) in either thetransport or the stationary condition.

In the illustrated embodiment of FIG. 1, cargo body 110 of trailer 100is an enclosed body. The cargo body 110 may be refrigerated and/orinsulated to transport temperature-sensitive cargo. While the conceptsof this disclosure are described in relation to a refrigerated trailer100, it will be understood that they are equally applicable to othervehicles generally, and more specifically to conventional trailers(e.g., dry freight trailers, flatbed trailers, commercial trailers,small personal trailers) and/or box or van semi-trailers, and the like.Accordingly, those skilled in the art will appreciate that the presentinvention may be implemented in a number of different applications andembodiments and is not specifically limited in its application to theparticular embodiments depicted herein.

Trailer 100 may have various features in common with the vehicles shownand described in International Publication No. WO 2016/137974 and U.S.Patent Application Publication No. 2017/0240217, the disclosures ofwhich are expressly incorporated herein by reference in their entirety.

2. Composite Materials

The cargo body 110 of trailer 100 may be constructed, at least in part,of composite materials. For example, the floor assembly 112, roof 114,right sidewall 116R, left sidewall 116L, and/or nose 118 of cargo body110 may be constructed of composite materials. As such, the floorassembly 112, roof 114, right sidewall 116R, left sidewall 116L, and/ornose 118 of cargo body 110 may be referred to herein as compositestructures.

Composite materials are generally formed by combining two or moredifferent constituents that remain separate and distinct in the finalcomposite material. Exemplary composite materials for use in thecomposite cargo body 110 include fiber-reinforced plastics (FRP), forexample carbon-fiber-reinforced plastics (CRP). Each composite structuremay be a single, unitary component, which may be formed from a pluralityof constituents or layers permanently coupled together. Other elementsof the cargo body 110 may be constructed of non-composite (e.g.,metallic) materials. For example, the rear door assembly 120 of thecargo body 110 may be constructed of metallic materials.

The composite construction of the cargo body 110 may present certainadvantages. First, because the composite structures may lack structuralmetallic components, the composite cargo body 110 may have a reducedheat loss coefficient (Ua) and improved thermal efficiency. Also, thecomposite cargo body 110 may operate to minimize outgassing of blowingagents, minimize air loss, and minimize water intrusion. Additionally,the composite cargo body 110 may be lighter in weight than a typicalmetallic cargo body, which may improve fuel efficiency. Further, thecomposite cargo body 110 may have fewer metallic structures than atypical cargo body, which may make the cargo body 110 less susceptibleto corrosion. Also, the composite cargo body 110 may include fewer partsthan a typical metallic cargo body, which may simplify construction,reduce inventory, and reduce variation in manufacturing. Further, thecomposite cargo body 110 may be suitable for use with sensitive cargo,including foodstuffs, because the composite materials may be inert toavoid reacting with the cargo and other materials and because thecomposite materials may be easy to clean and maintain to ensure properhygiene. As a result, the composite cargo body 110 may qualify as “foodgrade” equipment.

The composite structures of the present disclosure may contain one ormore structural supports or preforms. The preform may have a structuralcore that has been covered with an outer fabric layer or skin. The outerskin may be stitched or otherwise coupled to the underlying core and/orany surrounding layers. The core may be extruded, pultruded, orotherwise formed into a desired shape and cut to a desired length. In anexemplary embodiment, the core is a polyurethane foam material oranother foam material, and the outer skin is a non-woven spun bondpolyester material, a fiberglass fabric, or another suitable material.Advantageously, in addition to its structural effect, the foam core mayhave an insulating effect in certain applications, includingrefrigerated trucking applications. Exemplary preforms include PRISMA®preforms provided by Compsys, Inc. of Melbourne, Fla.

Both the core and the outer skin of the preform may be selected toaccommodate the needs of the particular application. For example, inareas of the final structure requiring more strength and/or insulation,a low-density foam may be replaced with a high-density foam or a hardplastic block. The individual preforms may also be sized, shaped, andarranged in a manner that accommodates the needs of the particularapplication. For example, in areas of the final structure requiring lessstrength, the preforms may be relatively large in size, with the foamcores spanning relatively large distances before reaching thesurrounding outer skins. By contrast, in areas of the final structurerequiring more strength, the preforms may be relatively small in size,with the foam cores spanning relatively small distances before reachingthe surrounding outer skins. Stated differently, the preforms may beshaped as relatively wide panels in areas of the final structurerequiring less strength and as relatively narrow support beams in areasof the final structure requiring more strength.

The composite structures of the present disclosure may also contain oneor more reinforcing materials or layers around the preforms. Eachreinforcing layer may contain reinforcing fibers and may be capable ofbeing impregnated and/or coated with a resin, as discussed further inSection 7 below. Suitable fibers include carbon fibers, glass fibers,cellulose, or polymers, for example. The fibers may be present in fabricform, which may be mat, woven, non-woven, or chopped, for example.Exemplary reinforcing layers include chopped fiber fabrics, such aschopped strand mats (CSM), and continuous fiber fabrics, such as 0°/90°fiberglass fabrics, +45°/−45° fiberglass fabrics, +60°/−60° fiberglassfabrics, 0° warp unidirectional fiberglass fabrics, and other stitchedfiber fabrics, for example. Such fabrics are commercially available fromVectorply Corporation of Phenix City, Ala. Exemplary fabrics include theE-LM 1810 fiberglass fabric with 0° unidirectional fibers, the E-LTM3610 fiberglass fabric with 0°/90° fibers, and the E-LTM 2408 fiberglassfabric with 0°/90° fibers, for example.

According to an exemplary embodiment of the present disclosure, aplurality of different reinforcing layers may be stacked together andused in combination. For example, a chopped fiber fabric (e.g., CSM) maybe positioned adjacent to a continuous fiber fabric. In this stackedarrangement, the chopped fibers may help support and maintain theadjacent continuous fibers in place, especially around corners or othertransitions. Also, the chopped fibers may serve as a web to resistcolumn-type loads in compression, while the adjacent continuous fibersmay resist flange-type loads in compression. Adjacent reinforcing layersmay be stitched or otherwise coupled together to simplify manufacturing,to ensure proper placement, and to prevent shifting and/or bunching.

3. Composite Floor Assembly

Floor assembly 112 is shown in more detail in FIGS. 2 and 3. Theillustrative floor assembly 112 includes a lower surface 200 that facesdownward toward the ground when in use. The illustrative floor assembly112 also includes an upper surface or platform 202 (see FIG. 1) thatfaces upward when in use to support cargo or other objects. Theillustrative floor assembly 112 has a generally rectangular outerperimeter 201 with a width W, a length L₁, and a height Hi between thelower surface 200 and the upper surface 202 (see FIG. 1), although thisshape may vary. As discussed in Section 2 above and Section 7 below,floor assembly 112 may be a composite structure that is constructed, atleast in part, of composite materials.

As further shown in FIGS. 2 and 3, the exemplary floor assembly 112includes a plurality of transverse composite beams 212. Illustratively,each of the plurality of transverse composite beams 212 is orientedgenerally orthogonal to longitudinal axis A. More specifically, each ofthe plurality of transverse composite beams 212 extend in a directionperpendicular to longitudinal axis A with longitudinal ends 213R, 213Lpositioned along outer perimeter 201 of floor assembly 112 and adjacentto sidewalls 116R, 116L, respectively. The individual transversecomposite beams 212 may be constructed in accordance with Section 2above and Section 7 below. Specifically, each transverse composite beams212 may be a preform of a structural core wrapped in an outer skin.

The plurality of transverse composite beams 212 includes a first subsetof rearward beams 214, specifically rearward beams 214 a-i, and a secondsubset of rearward beams 216, specifically rearward beams 216 a-e. Inthe exemplary embodiment shown, some of the beams 214, 216 arelongitudinally spaced apart from one another along longitudinal axis A.More specifically, some of the beams 214, 216 are intermixed with andseparated by the remainder of the plurality of transverse compositebeams 212 such that some of the beams 214, 216 are longitudinally spacedapart along a rear portion 113 of cargo body 110. Others of the beams214, 216, specifically beams 214 a, 216 a, are positioned immediatelyadjacent to each other.

As discussed in Section 2 above, the individual transverse compositebeams 212, 214, 216 may be sized, shaped, and arranged in a manner thataccommodates the needs of the particular application. For example, arelatively large number of small, closely-spaced beams may be used forhigh-weight/high-strength applications, whereas a relatively smallnumber of large and/or spaced-apart beams may be used forlow-weight/low-strength applications.

4. Longitudinal Beams

As shown in FIGS. 2 and 3, cargo body 110 includes a first and secondlongitudinal main beam 150L, 150R extending downward from lower surface200 of floor assembly 112 along a length L₂ of cargo body 110 parallelto longitudinal axis A and oriented generally orthogonal to theplurality of transverse composite beams 212, 214, 216. Longitudinal mainbeams 150L, 150R are illustratively positioned laterally inward oflongitudinal ends 213R, 213L of the plurality of composite beams 212,214, 216, which correspond to sidewalls 116R, 116L of cargo body 110(see FIG. 1). In the exemplary embodiment shown, longitudinal main beams150L, 150R are positioned laterally intermediate longitudinal axis A andthe respective longitudinal end 213R, 213L. That said, the lateralposition of longitudinal main beams 150L, 150R relative to longitudinalaxis A and longitudinal ends 213R, 213L lateral sides of cargo body 110may be adjusted depending on the specific application and components ofcargo body 110. Furthermore, the individual longitudinal main beams150L, 150R may be constructed in accordance with Section 2 above andSection 7 below. Specifically, each longitudinal main beam 150L, 150Rmay be a preform of a structural core wrapped in an outer skin.

Longitudinal beams 150L, 150R extend along length L₂ of floor assembly112. As shown in FIG. 2, length L₂ is a portion of overall length L₁ ofcargo body 110. More specifically, longitudinal main beams 150L, 150Rextend along longitudinal axis A from proximate front end 102 of cargobody 110 to a slide rail assembly (not shown). In the exemplaryembodiment shown, longitudinal main beams 150L, 150R extendlongitudinally from proximate coupler assembly 130 and proximate landinggear assembly 132 without extending entirely to front end 102 of trailer100 to approximate a rearward portion of trailer 100 where a slide railassembly (not shown) couples to floor assembly 112 without extendingentirely to rear end 104 of cargo body 110. An advantage, among others,of longitudinal main beams 150L, 150R is that longitudinal main beams150L, 150R provide stiffness along length L₂ of floor assembly 112.

In the exemplary embodiment shown, cargo body 110 includes additionallongitudinal beams 152L, 152R, 153. Longitudinal beams 152L, 152R, 153extend along a shorter length of floor assembly 112 than length L₂ oflongitudinal main beams 150L, 150R. More specifically, longitudinalbeams 152L, 152R, 153 are positioned proximate front end 102 of cargobody 110 without extending entirely to coupler assembly 130 or rear end104 of cargo body 110. In the exemplary embodiment shown, longitudinalbeams 152L, 152R, 153 provide a coupling surface for components of cargobody 110 such as, for example, landing gear assembly 132 and fuel tankassembly 134 (see FIG. 1). Another advantage, among others, oflongitudinal beams 152L, 152R, 153 is that longitudinal beams 152L,152R, 153 provide additional stiffness to floor assembly 112 near frontend 102 (i.e., the area of landing gear assembly 132 and fuel tankassembly 134).

Similar to the transverse composite beams 212, the individuallongitudinal beams 150L, 150R, 152L, 152R, 153 may be sized, shaped, andarranged in a manner that accommodates the needs of the particularapplication. For example, in another embodiment, longitudinal beams152L, 152R, 153 are sized and arranged to accommodate an additional fueltank assembly or other accessory positioned, for example, laterallyopposite fuel tank assembly 134.

5. Embedded Hardpoint Connectors

Floor assembly 112 may include one or more embedded hardpoint connectors300, as shown in FIGS. 2 and 3. Connectors 300 may serve as fasteners oranchors for mechanically coupling other components of trailer 100 tofloor assembly 112, such as rear door assembly 120 (FIG. 1), a couplerassembly 130, landing gear assembly 132 (FIG. 1), fuel tank assembly 134(FIG. 1), a slide rail assembly (not shown), and/or a suspensionassembly (not shown), for example.

Each connector 300 may be configured to receive one or more mechanicalfasteners (not shown) from the adjacent component. Suitable mechanicalfasteners include bolts, screws, rivets, and nails, for example. Incertain embodiments, connectors 300 may include pre-tapped holes (notshown) capable of receiving the mechanical fasteners. Depending on theneeds of the particular application, the mechanical fasteners may beused alone or in combination with structural adhesives. The mechanicalfasteners may be desired when the adjacent component will be susceptibleto peeling, whereas structural adhesive may be desired when the adjacentcomponent will be susceptible to shear loads. When used alone, themechanical fasteners may facilitate efficient and inexpensive assemblyand repairs of trailer 100. When used in combination with structuraladhesive, the mechanical fasteners may also serve as clamps to stabilizetrailer 100 during curing of the structural adhesive.

In the exemplary embodiment of FIGS. 2 and 3, connectors 300 areillustratively embedded in a select group of beams of the plurality oftransverse composite beams 212. More specifically, connectors 300 areembedded in beams 214, 216, which comprise a first and second subset ofthe plurality of beams 212. The remaining beams 212 may lack embeddedconnectors 300. In an alternative embodiment, some or all of theremaining beams 212 may include embedded connectors 300.

As referenced above, one or more beams 212 lacking embedded connectors300 may be arranged between some of the beams 214, 216 having embeddedconnectors 300 such that some of the connectors 300 are longitudinallyspaced apart along cargo body 110. Others of the beams 214, 216,specifically beams 214 a, 216 a, may be positioned immediately adjacentto each other, such that others of the embedded connectors 300 arelongitudinally adjacent to each other.

Illustratively, connectors 300 comprise a generally planar body or plateand are embedded in lower surface 200 of composite floor assembly 112,more specifically within beams 214, 216 themselves. In an alternativeembodiment, connectors 300 are embedded in another surface or span twoor more surfaces of beams 214, 216. Accordingly, connectors 300 may alsobe C-shaped, T-shaped, pi-shaped, bent, tubular, or other suitableshapes. Connectors 300 may be embedded in beams 214, 216 duringformation of the accordance with Section 7 below.

In the exemplary embodiment shown in FIG. 3, each beam 214, 216 includesa plurality of embedded connectors 300, illustratively between two andthree embedded connectors 300. Generally, connectors 300 are spacedapart from one another along the longitudinal length of each beam 214,216. For example, connectors 300 may be positioned intermediatelongitudinal axis A and a respective longitudinal end 213L, 213R ofbeams 214, 216. More specifically, connectors 300 are positionedlaterally inward of longitudinal ends 213L, 213R of beams 214, 216(corresponding to the lateral sidewalls 116L, 116R of cargo body 110(see FIG.

In the exemplary embodiment shown, beams 214 include connectors 300L,300R and beams 216 include connectors 300L, 300M, 300R. Regarding beams214, 216, connectors 300L, 300R are positioned laterally intermediatelongitudinal axis A and a respective longitudinal end 213L, 213R ofbeams 214, 216. Regarding beams 216, connectors 300M are positionedlaterally intermediate connectors 300L, 300R. More specifically,connectors 300M are positioned along longitudinal axis A when beams 216are arranged as part of floor assembly 112. That said, the position andnumber of connectors 300 along the length of each beam 214, 216 may beadjusted for the required application. Moreover, the subsets of beams214, 216 with embedded connectors 300 may be more or fewer than thenumber of selected beams 214, 216 shown in FIG. 3.

Connectors 300 may be constructed of metallic materials (e.g., steel,aluminum, titanium), polymeric materials, wood, or composite materials.In certain embodiments, connectors 300 are constructed of materialswhich are dissimilar from the composite material used to construct thecorresponding beams. Connectors 300 may be fabricated by extrusion,pultrusion, sheet forming, roll forming, and/or casting, for example.Connectors 300 may also be single-piece or multi-piece constructs. Formulti-piece constructs, the pieces may be welded, mechanically fastened,adhered, snap-fit, or otherwise coupled together.

6. Conduits

Floor assembly 112 may include one or more conduits 400, as shown inFIGS. 2 and 3. Conduits 400 may serve to internally route vehiclecomponents, such as air hoses H and/or electrical cables C, along alength of composite floor assembly 112. Conduits 400 may also serve toroute fuel lines (not shown) along a length of composite floor assembly112, but such fuel lines would be separated from any electrical cablesC.

In the exemplary embodiment shown in FIG. 2, floor assembly 112 includesconduits 400L, 400R positioned laterally opposite from one another. Morespecifically, conduit 400L is coupled to the left-side perimeter 201 offloor assembly 112 along longitudinal ends 213L of beams 212, whichgenerally correspond to sidewall 116L of trailer 100. Similarly, conduit400R is coupled to the right-side perimeter 201 of floor assembly 112along longitudinal ends 213R of beams 212, which generally correspond tosidewall 116R of trailer 100. In another embodiment, floor assembly 112includes a single conduit 400, which could be coupled to either oflongitudinal ends 213L, 213R.

Conduits 400L, 400R illustratively extend along a length L₃ of floorassembly 112 parallel to and spaced apart from longitudinal axis A. Inthe exemplary embodiment shown, length L₃ is less than length L₁ offloor assembly 112. More specifically, conduits 400L, 400R extend fromproximate coupler assembly 130 at front end 102 of trailer 100 toproximate rear end 104 of trailer 100. Furthermore, length L₃ is longerthan length L₂ of main longitudinal beams 150L, 150R. In an alternativeembodiment, conduits 400L, 400R (or a single conduit 400) may extendfrom proximate front end 102 to proximate rear end 104 of trailer 100 orextend along a length of floor assembly 112 shorter or longer thanlength L₃ of conduits 400L, 400R of FIGS. 2 and 3.

Turning now to FIGS. 4 through 7, a detailed view of conduit 400R isshown. In FIGS. 4 through 6, conduit 400R is shown coupled to floorassembly 112. Conduit 400R includes a first internal cavity 420 and asecond internal cavity 430 extending along a length of conduit 400Rgenerally parallel to longitudinal axis A. Illustratively, internalcavities 420, 430 extend from a first longitudinal end 402R of conduit400R to a second longitudinal end 404R spaced apart from firstlongitudinal end 402R along length L₃ of conduit 400R (see FIG. 2).Therefore, in the exemplary embodiment shown, internal cavities 420, 430extend longitudinally along length L₃ of conduit 400R. In an alternativeembodiment, internal cavities 420, 430 may extend along a portion oflength L₃. For example, internal cavities 420, 430 may extend from firstlongitudinal end 402R to a longitudinal location along conduit 400Rintermediate longitudinal ends 402R, 404R. Conduit 400L may be coupledto floor assembly 112 in a similar manner and include the same orsimilar internal cavities as conduit 400R.

Turning to FIG. 7, conduit 400R has a prismatic shape with a constantand geometric transverse cross-sectional area along its length. Morespecifically, conduit 400R includes an exterior boundary 405 defined bya first vertical wall 406, a second horizontal wall 408, and a thirdoblique wall 410. In the exemplary embodiment shown, third wall 410intersects first and second walls 406, 408 to form a conduit having agenerally triangular transverse cross-sectional area. More specifically,a first end 415 of second wall 408 intersects a first end 413 of firstwall 406, and a first end 417 of third wall 410 intersects second wall408 intermediate the first end 415 and a second end 416 of second wall408. As a result, a portion 409 of second wall 408, including second end416, extends past where first end 417 of third wall 410 intersectssecond wall 408. In addition, a second end 418 of third wall 410intersects a second end 414 of first wall 406. Illustratively, secondwall 408 perpendicularly intersects first wall 406, and third wall 410obliquely intersects first and second walls 406, 408. In an alternativeembodiment, second wall 408 may intersect first wall 406 and third wall410 may intersect first and second walls 406, 408 at different anglesthan those shown in the exemplary embodiment.

Conduit 400R further includes a midwall 412 confined within exteriorboundary 405 and coupled to at least one of walls 406, 408, 410. In theexemplary embodiment shown, midwall 412 is coupled to third wall 410 andextends from an intersection between walls 406, 408. More specifically,midwall 412 is coupled to an approximate mid-point of third wall 410between ends 417, 418 and extends from the intersection of first end 413of first wall 406 with first end 415 of second wall 408. Midwall 412cooperates with exterior boundary 405 to define internal cavities 420,430. Specifically, midwall 412, a portion of second wall 408, and aportion of third wall 410 define internal cavity 420. In an alternativeembodiment, internal cavity 420 may be defined by midwall 412, theentirety of second wall 408, and a portion of third wall 410. Inaddition, internal cavity 430 is defined by midwall 412, first wall 406,and a portion of third wall 410. In an alternative embodiment, conduit400R may include more or fewer internal cavities. Moreover, it iscontemplated that the size, shape, and number of internal cavities maybe adjusted based on, for example, the intended application of conduits400L, 400R.

Internal cavity 420 is configured to route at least one vehiclecomponent, such as, for example, an air hose H and/or an electricalcable C. Therefore, internal cavity 420 is sized and shaped to receiveat least one vehicle component for routing along a length of conduit400. In one example, internal cavity 420 routes an electrical cable C tosupply power from the tractor (not shown) at front end 102 to rear end104 of trailer 100 (FIG. 1). In a further embodiment, internal cavity420 routes anti-locking braking system (“ABS”) control wires for trailerair brakes. In another example, internal cavity routes an air hose H tosupply pressure to trailer air brakes from a front end 102 of trailer100 (FIG. 1). An advantage, among others, of routing at least onevehicle component through internal cavity 420 is that the at least onevehicle component can be more easily replaced or maintained relative tomolding the vehicle component into floor assembly 112.

Illustratively, conduits 400L, 400R route a plurality of vehiclecomponents to various longitudinal locations along length L₃ of trailer100, including the first longitudinal end 402R of each conduit 400L,400R, the second longitudinal end 404R of each conduit 400L, 400R, andintermediate locations therebetween. For example, a fuel line routedthrough one of internal cavities 420, 430 to a refrigeration unitlocation proximate front end 102 of trailer 100 may enter conduits 400L,400R proximate fuel tank assembly 134. In another example, an electricalwire C for a mid-trailer marker light, which may be mounted verticallybelow base rails 117L, 117R, may exit conduits 400L, 400R proximate amid-length of trailer 100. In a further example, the air hose H and theABS control wires may exit conduits 400L, 400R longitudinally forward ofthe slide rail assembly (not shown). In yet another example, anelectrical wire C for a rear light of trailer 100 may be routed throughconduits 400L, 400R to proximate rear end 104 of trailer 100.

In order to accommodate the routing of the plurality of vehiclecomponents, second wall 408 or another suitable surface of each conduit400L, 400R may include a plurality of apertures (not shown)longitudinally spaced along length L₃ of conduits 400L, 400R. Theplurality of apertures in second wall 408 may be sized and shaped topermit at least one of the plurality of vehicle components to passthrough, thereby entering or exiting the conduit 400L, 400R at thedesired longitudinal location, either directly or via a coupler. It iscontemplated that conduits 400L, 400R may include extra apertures thatare not used (i.e., that remain empty or are sealed or plugged) for aparticular application. For example, second wall 408 may include anaperture proximate fuel tank assembly 134 that is not used when conduits400L, 400R are not used to route fuel lines.

Internal cavity 430 is configured to receive a plurality of mechanicalfasteners 432 (see FIG. 6), such as, for example, bolts, screws, orrivets. Illustratively, mechanical fasteners 432 are inserted into firstwall 406 such that mechanical fasteners 432 extend into internal cavity430 without extending into internal cavity 420. Therefore, in oneembodiment, first wall 406 may include a plurality of apertures (notshown) sized and shaped to receive a corresponding one of the pluralityof mechanical fasteners 432. An advantage, among others, of midwall 412is that midwall 412 protects the at least one vehicle component routedthrough internal cavity 420 from mechanical fasteners 432 insertedthrough first wall 406 into internal cavity 430. The coupling ofmechanical fasteners 432 to conduit 400 is described further below.

In the exemplary embodiment shown in FIGS. 4-7, conduit 400R comprises atriangular transverse cross-sectional area. Other transversecross-sectional areas, however, are contemplated. For example, thetransverse cross-sectional area may be a square or rectangulartransverse cross-sectional area. More specifically, exterior boundary405 may be defined by more than three walls. For example, exteriorboundary 405 may be further defined by a fourth wall. The fourth wallmay intersect first wall 406 and third wall 410 to form a conduit havinga square or rectangular transverse cross-sectional area. That is, secondwall 408 may perpendicularly intersect first wall 406, third wall 410may perpendicularly intersect second wall 408, and the fourth wall mayperpendicularly intersect first wall 406 and third wall 410. In afurther alternative embodiment, midwall 412 is coupled to first wall 406and the fourth wall. At least one of walls 406, 408, 410 and the fourthwall may be coupled to floor assembly 112.

Referring back to FIGS. 4 and 5, longitudinal ends 213R of floorassembly 112 cooperate to define a first or right side 204R of floorassembly 112. In the exemplary embodiment shown, first side 204R isangled with respect to lower surface 200 and upper surface 202 of floorassembly 112. More specifically, upper surface 202 extends laterallyfarther from longitudinal axis A than lower surface 200. Third wall 410of conduit 400R comprises a complementary shape to first side 204R. Thatis, third wall 410 comprises a complementary angle to the angle of firstside 204R in order to create a mating surface with first side 204R. Inaddition, portion 409 of second wall 408 extends underneath and supportsa portion of lower surface 200 of floor assembly 112. An advantage,among others, of third wall 410 comprising a complementary angle to theangle of first side 204R is a more robust attachment of conduit 400R tofloor assembly 112. This more robust attachment is due, at least inpart, to the increase in contact area of third wall 410 and first side204R when third wall 410 and first side 204R are angled relative tolower surface 200 and upper surface 202. Longitudinal ends 213L of floorassembly 112 may likewise define a second or left side 204L (FIG. 2) offloor assembly 112 comprising a complementary shape to that of conduit400L.

Turning now to FIG. 6, conduit 400R is shown coupled to sidewall 116R.More specifically, cargo body 110 further includes a first base rail117R extending along a length of cargo body 110 parallel to and spacedapart from longitudinal axis A. Illustratively, first base rail 117Rextends from proximate front end 102 to proximate rear end 104 oftrailer 100. First base rail 117R may comprise, for example, a metallicmaterial or a composite material. An upper portion 437 of first baserail 117R is coupled to sidewall 116R. In the exemplary embodimentshown, upper portion 437 of first base rail 117R is adhered to sidewall116R using, for example, a structural adhesive. In an alternativeembodiment, upper portion 437 may be coupled to sidewall 116R using, forexample, a plurality of mechanical fasteners or a combination ofstructural adhesive and mechanical fasteners. A lower portion 438 offirst base rail 117R is coupled to conduit 400R. In the exemplaryembodiment shown, lower portion 438 is coupled to conduit 400R using theplurality of mechanical fasteners 432. Mechanical fasteners 432illustratively include a head end 434 positioned laterally outside offirst base rail 117R and a terminal end 436 positioned laterally outsideof midwall 412. In this way, terminal end 436 is positioned withininternal cavity 430 and is isolated from internal cavity 420 by midwall412. In an alternative embodiment, lower portion 438 of first base rail117R may be adhered to conduit 400R using, for example, a structuraladhesive or a combination of structural adhesive and mechanicalfasteners. As shown in FIG. 6, conduit 400R is aligned beneath sidewall116R, such that conduit 400R and floor assembly 112 are located withinthe profile of sidewall 116R and base rail 117R is located slightlyoutside the profile of sidewall 116R.

In a further alternative embodiment, first base rail 117R may beintegrally formed with conduit 400R. In this way, first base rail 117Rand conduit 400R may form a unitary body. When either first base rail117R is integrally formed with conduit 400R or only a structuraladhesive is used to couple first base rail 117R to conduit 400R,mechanical fasteners 432 may not be needed. As a result, internal cavity430 may be configured to route one or more vehicle components separatelyfrom the one or more vehicle components routed through internal cavity420. For example, internal cavity 430 may be configured to route a fuelline from proximate fuel tank assembly 134 to a refrigeration unitproximate front end 102 of trailer 100. In this way, the fuel line maybe kept separate from any vehicle components routed through internalcavity 420. In an alternative embodiment, one or more vehicle componentmay be routed through internal cavities 420, 430 of conduit 400R whileone or more different vehicle components may be routed through theinternal cavity or cavities of conduit 400L.

Cargo body 110 may further include a second base rail 117L (FIG. 1)extending along a length of cargo body 110 parallel to and spaced apartfrom longitudinal axis A. Illustratively, the second base rail 117Lextends from proximate front end 102 to proximate rear end 104 oftrailer 100. Similar to first base rail 117R, the second base rail 117Lmay comprise a metallic or composite material. In addition, an upperportion of the second base rail 117L may be adhered to sidewall 116Lusing, for example, a structural adhesive. In an alternative embodiment,the upper portion of the second base rail 117L may be coupled tosidewall 116L using, for example, a plurality of mechanical fasteners ora combination of mechanical fasteners and structural adhesive. A lowerportion of the second base rail 117L may be coupled to conduit 400Lusing, for example, a plurality of mechanical fasteners. In analternative embodiment, the lower portion of the second base rail 117Lmay be coupled to conduit 400L using, for example, a structural adhesiveor a combination of structural adhesive and mechanical fasteners. Anadvantage, among others, of conduits 400L, 400R is that conduits 400L,400R provide additional stiffness and strength to base rails 117L, 117Ralong a common length of base rails 117L, 117R and conduits 400L, 400R,respectively. For example, conduits 400L, 400R provide stiffness andstrength along length L₃ of base rails 117L, 117R, respectively.

In the exemplary embodiment shown, conduits 400L, 400R are adhered tofloor assembly 112 using, for example, a structural adhesive. Theadhesive may be placed along portion 409 of second wall 408 for adhesionto lower surface 200 of floor assembly 112 and/or along third wall 410for adhesion to longitudinal ends 213L, 213R of floor assembly 112. Anadvantage, among others, of coupling conduits 400L, 400R to longitudinalends 213L, 213R of floor assembly 112 is that conduits 400L, 400R mayprotect longitudinal ends 213L, 213R during handling of floor assembly112 and the coupling of sidewalls 116L, 116R to floor assembly 112.Another advantage, among others, of coupling conduits 400L, 400R tolongitudinal ends 213L, 213R of floor assembly 112 is that conduits400L, 400R help square floor assembly 112. More specifically, conduits400L, 400R help keep transverse composite beams 212, 214, 216 straightand flat relative to one another and help keep sidewalls 116L, 116Rgenerally perpendicular to floor assembly 112. In an alternativeembodiment, conduits 400L, 400R may be coupled to longitudinal ends213L, 213R using a plurality of mechanical fasteners, such as, forexample, bolts, screws, or rivets, or using a combination of structuraladhesive and mechanical fasteners. In a further embodiment, conduits400L, 400R may be coupled to lower surface 200 or upper surface 202 offloor assembly 112. Furthermore, conduits 400L, 400R may be coupled todifferent surfaces of floor assembly 112 relative to one another. In afurther alternative embodiment, conduits 400L, 400R are molded intofloor assembly 112 during construction of floor assembly 112 inaccordance with Section 2 above and Section 7 below.

7. Composite Molding Process

Turning now to FIGS. 8 and 9, the composite structures of the presentdisclosure may be formed by a molding process 350, as discussed furtherbelow.

The illustrative method 350 involves fabricating each transverse beam212, 214 a-216 a-e as a preform and then incorporating the preforms intothe final floor assembly 112. At step 352, a mold 370 having a desiredshape is provided. At step 354, interior surfaces of mold 370 arecovered with outer skins 218, 220. Outer skins 218, 220 may comprise afiberglass fabric, for example. Moreover, outer skins 218, 220 may be ofthe same or different fabric weight. For example, outer skin 220 may beof a heavier fabric weight than outer skin 218. At step 356, any desiredconnectors 300 are placed inside outer skins 218, 220 in mold 370. Withrespect to the illustrative beam 214 a of FIGS. 2 and 3, for example,connectors 300L (not shown in FIG. 9), 300R are spaced apart from oneanother along the intended longitudinal length of beam 214 a within mold370. Step 356 may be omitted when forming a transverse beam 212 thatlacks connectors 300. At step 358, expandable core material 222 isinjected or otherwise introduced into the outer skins 218, 220 tocontact connectors 300, if present. At step 360, the core material 222expands and cures within the outer skins 218, 220 and around connectors300, if present, which holds connectors 300 in place. At step 362, apreform resembling the desired beam 212, 214 a-i, 216 a-e is removedfrom mold 370. At step 363, longitudinal ends 213R, 213L of eachtransverse beam 212, 214 a-i, 216 a-e may be cut or otherwise shaped tocompliment conduits 400R, 400L. Step 363 may be omitted whenlongitudinal ends 213R, 213L are formed in the complimentary shapeduring the prior molding steps 352-362. At step 364, the preform isincorporated into the final floor assembly 112, which may involvearranging the preform with other preforms (e.g., beam 214 a of FIG. 9may be arranged with other beams 212, 214 a-i, 216 b-e) and reinforcinglayers, wetting the materials with at least one resin and a catalyst toimpregnate and/or coat the materials, and curing the materials to formthe final floor assembly 112. At step 366, conduits 400R, 400L areadhered or otherwise coupled to longitudinal ends 213R, 213L oftransverse beams 212, 214 a-i, 216 a-e.

The resin used to construct the composite structure may be a typicalthermoset resin, a co-cure resin containing a plurality of individualco-curing resins which may be selectively distributed throughout thecomposite structure during the molding process, or a combinationthereof. Such co-cure resins may comprise one or more elastomercomponents, such as urethane, co-cured with one or more resincomponents, such as a vinyl ester, epoxy, or unsaturated polyestercomponents. Exemplary co-cure resins are disclosed in U.S. Pat. No.9,371,468 and U.S. Publication No. 2016/0263873, the disclosures ofwhich are hereby incorporated by reference in their entirety. As usedherein, “co-cured” refers to the reactions involved in curing theelastomer components take place essentially concurrently with thereactions involved in curing the one or more resin components. Incertain embodiments, areas of the composite structure that will besusceptible to high stress may receive a resin with a relatively higherpolyurethane content for strength, whereas other areas of the compositestructure that provide bulk and section modulus may receive a lower costrigid, polyester-based resin, such as an isophthalic polyester resin.

Additional information regarding the construction of compositestructures is disclosed in the following patents and published patentapplications, each of which is incorporated by reference in its entiretyherein: U.S. Pat. Nos. 5,429,066, 5,664,518, 5,800,749, 5,830,308,5,897,818, 5,908,591, 6,004,492, 6,013,213, 6,206,669, 6,496,190,6,497,190, 6,543,469, 6,723,273, 6,755,998, 6,869,561, 6,911,252, and8,474,871, and U.S. Publication No. 2014/0262011.

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractices in the art to which this invention pertains.

What is claimed is:
 1. A cargo body, comprising: a composite floorassembly having a first longitudinal end and a second longitudinal endspaced apart from the first longitudinal end along a floor longitudinalaxis; a first composite side wall extending in a direction parallel tothe longitudinal axis; a first conduit coupled to the composite floorassembly and located within a profile of the first composite side wall.2. The cargo body of claim 1, wherein the first conduit includes a firstand a second internal cavity, the first and second internal cavities ofthe first conduit extending along a length of the first conduit parallelto the floor longitudinal axis.
 3. The cargo body of claim 1, furthercomprising: a second composite side wall extending in a directionparallel to the longitudinal axis; and a second conduit coupled to thecomposite floor assembly and located within a profile of the secondcomposite side wall, the second conduit spaced laterally opposite thefirst conduit and including a first and a second internal cavity, thefirst and second internal cavities of the second conduit extending alonga length of the second conduit parallel to the floor longitudinal axis.4. The cargo body of claim 2, wherein the composite floor assemblyincludes a coupler assembly having a king pin proximate the firstlongitudinal end, and the first and second internal cavities extendalong the first conduit from proximate the coupler assembly to thesecond longitudinal end of the composite floor assembly.
 5. The cargobody of claim 4, wherein the first conduit extends from proximate thecoupler assembly to the second longitudinal end of the composite floorassembly.
 6. The cargo body of claim 2, wherein the first and secondinternal cavities extend from a first longitudinal end of the firstconduit to a second longitudinal end of the first conduit, the secondlongitudinal end spaced apart from the first longitudinal end along aconduit longitudinal axis.
 7. The cargo body of claim 2, wherein thefirst internal cavity is sized and shaped to receive at least one of anair hose and an electrical cable.
 8. The cargo body of claim 7, whereinthe second internal cavity is sized and configured to receive a fuelline.
 9. The cargo body of claim 1, wherein the composite floor assemblyincludes an upper surface and a lower surface opposite the uppersurface, and the first conduit includes a lower wall extending along atleast a portion of the length of the first conduit, the lower wallsupporting a portion of the lower surface.
 10. The cargo body of claim2, further comprising a first base rail having an upper portion coupledto the first side wall and a lower portion coupled to the first conduitwith a plurality of mechanical fasteners that extend into the secondinternal cavity without extending into the first internal cavity. 11.The cargo body of claim 10, wherein each of the plurality of mechanicalfasteners comprises: a head end positioned laterally outside of thefirst base rail; and a terminal end positioned laterally outside of amidwall that separates the first and second internal cavities.
 12. Thecargo body of claim 10, wherein the upper portion of the first base railis adhered to the first composite side wall.
 13. A cargo body,comprising: a composite floor assembly having a plurality of transversecomposite beams oriented generally perpendicular to a longitudinal axisof the composite floor assembly, a first longitudinal end of each of theplurality of transverse composite beams defining a first side of thecomposite floor assembly and having a first shape; and a first conduitcoupled to the first side of the composite floor assembly and includinga first wall having a second shape complementary to the first shape. 14.The cargo body of claim 13, wherein a second longitudinal end of each ofthe plurality of transverse composite beams defines a second side of thecomposite floor assembly opposite the first side, the second sideincluding a third shape, and a second base rail is coupled to the secondside and includes a second wall having a fourth shape complementary tothe third shape.
 15. The cargo body of claim 13, wherein the compositefloor assembly includes an upper surface and a lower surface oppositethe upper surface, the first shape of the composite floor assemblycomprises a first surface angled relative to the upper surface and thelower surface, and the second shape of the first conduit comprises anangled surface complementary to the first surface.
 16. A conduit for afloor assembly of a cargo body, comprising: an exterior boundary definedby at least a first wall, a second wall, and a third wall, the secondwall intersecting the first wall and the third wall intersecting atleast one of the first and second walls; a midwall coupled to at leastone of the first, second, and third walls, the midwall defining a firstinternal cavity and a second internal cavity.
 17. The conduit of claim16, wherein the second wall perpendicularly intersects the first walland the third wall obliquely intersects the first and second walls. 18.The conduit of claim 17, wherein the midwall extends from anintersection between the first and second walls to the third wall. 19.The conduit of claim 16, wherein each of the first, second, and thirdwalls includes a first end and a second end opposite the first end, thefirst end of the second wall intersecting the first end of the firstwall, a first end of the third wall intersecting the second wallintermediate the first end and the second end of the second wall. 20.The conduit of 19, wherein the second end of the third wall intersectsthe first wall at the second end of the first wall.
 21. The conduit ofclaim 16, wherein the first internal cavity is sized and shaped toreceive at least one of an air hose and an electrical cable and thesecond internal cavity is sized and shaped to receive a plurality ofmechanical fasteners inserted into the first wall.
 22. A cargo bodyhaving a front end, a rear end, a longitudinal axis extending from thefront end to the rear end, a left side, and a right side, the cargo bodycomprising: a composite floor assembly; a first composite sidewallextending in a direction parallel to the longitudinal axis; a first baserail coupling the first composite sidewall to the composite floorassembly; a first conduit disposed between the first base rail and thecomposite floor assembly, the first conduit including: a first internalcavity configured to route at least one vehicle component; and a secondinternal cavity configured to receive a plurality of fasteners thatcouple the first base rail to the first conduit.
 23. The cargo body ofclaim 22, further comprising: a second composite sidewall positionedlaterally opposite the first composite sidewall; a second base railcoupling the second composite sidewall to the composite floor assembly;and a second conduit disposed between the second base rail and thecomposite floor assembly.
 24. The cargo body of claim 22, wherein the atleast one vehicle component is an air hose or an electrical cable. 25.The cargo body of claim 22, wherein the first conduit is adhered to thecomposite floor assembly.